Grain distribution apparatus and method

ABSTRACT

A grain distributor including a timer coupled to a distribution spout that generates a series of particular time values. The control processor is programmed with an algorithm to pivot the distribution spout and to receive and record signals from the sensor as the sensor confronts each of the code clusters and each of the proof windows. The control processor is programmed with the algorithm to associate each signal from each code cluster with a particular time value generated by the timer and to memorize the particular time value associated with each code cluster in a long term memory and the control processor being programmed with the algorithm to associate each signal from each of the proof windows in a long term memory. The grain distributor is also self programming.

FIELD OF THE INVENTION

The invention relates generally to grain distributors including carouselstyle grain distributors and pendulum style grain distributors. Moreparticularly, the invention relates to the electronic control ofcarousel style or pendulum style grain distributors.

BACKGROUND OF THE INVENTION

Grain distributors are used in grain elevators to distribute grain amongone of a plurality of receiving ducts that lead to storage bins orsilos. In a grain distributor, a housing encloses a distribution spoutthat is rotated by a drive motor among multiple discharge positions.Each of the discharge positions is located at a receiving duct. In theprior art, a control wheel is connected to the spout and rotates alongwith the spout to the various selectable discharge positions.

In some grain distributors, the control wheel includes a plurality ofcode clusters that can be sensed by sensors, for example, inductivesensors. A code cluster is associated with each discharge position. Eachof the code clusters has a unique series of data digits and a series ofsequencing digits adjacent to the data digits. The data digits andsequencing digits are read as the digits pass by a sensor that includesa first sensor unit and a second sensor unit. The sensor units areoperably connected to a control processor for identifying the positionof the spout. The control processor allows the data digits to be readonly when a sequencing digit is also being read. When a particulardischarge position is selected at the control console, the controlprocessor operates the drive motor until the data digits correspondingto the desired discharge position have been sensed by the sensors. Thecontrol processor then continues to operate the drive motor for apre-selected period of time and stops the motor at a point where thedischarge spout should be properly positioned at the selected dischargereceiving duct.

The coded portion of the control wheel also includes a position proofwindow or position proof digit for each coded portion. Each of theposition proof windows is positioned on the coded portion so as toconfront one of the sensors when the discharge spout has been properlypositioned at each discharge position. The sensor detects the proofwindow to confirm that the discharge spout is aligned with the selectedreceiving duct at the selected discharge position.

The value of grain crops is closely tied to the consistency of the graindelivered. The accidental addition of a different type of grain to agrain crop can cause a dramatic reduction in the value of the crop. Forexample the inadvertent mixing of soybeans with corn at the grainelevator can lead to a significant financial loss. Accordingly, it isimportant that the distribution spout be properly aligned with theappropriate receiving duct to avoid the unintentional intermixing ofdifferent grain products, which can result in significant losses to theoperator of the grain elevator.

Because of the size of grain elevators, it is not uncommon for thecontrol panel for the grain distributor to be located several hundredfeet away from the grain distributor itself. The grain distributortypically is positioned near the highest point of the grain elevator,while the control computer or panel is typically located at groundlevel.

Once a grain distributor is installed, it is necessary to calibrate thesensors and electronics and program the computer so that the graindistributor can be accurately controlled from the computer panel. In theprior art, this is accomplished by stationing a worker in a locationwhere the worker can observe the location of the spout in the graindistributor.

The worker is equipped with a radio and a work light and observes themotion of the grain distributor while it is being controlled by thecomputer and relays messages to the programmers far below to adjust theposition of the distribution spout relative to each receiving duct sothat these positions may be programmed in a computer memory for futureuse. For example, the observer will report to the programmer that thespout is located in proper alignment with a discharge position. Morelikely, however, the observer will report that the spout is misalignedand needs to be advanced a small distance. The programmer adjusts theposition of the spout based on the observer's instructions. If thedistance is misjudged and overshot, the observer will instruct theprogrammer to move the spout backward somewhat. The programmer does so.Once the spout is aligned with a particular discharge position theposition is programmed into memory. This process is repeated for eachposition of the spout until all proper spout positions are properlyaligned and placed into memory

This situation is time consuming and labor intensive because the workermust position themselves so that they can see the grain distributor andcommunicate with the programmers by radio. The spout of the graindistributor may weigh 1200 to 1500 pounds and when in motion must beapproached with caution.

Distribution spouts are sometimes moved by an electric brake motor. Anelectric brake motor is an electric motor that includes a brake that isapplied to the motor shaft or armature when power is no longer appliedto the motor in order to secure the brake motor and the distributionspout in position until actuated again. Brake motors are known to befairly reliable at stopping the spout at a desired location. The brakemotor stops the motion of the spout as instantly as possible. Whilebrake motors are fairly reliable, they are sometimes not sufficientlyreliable to prevent unintended mixing of types of grain. Coasting of thebrake motor and spout when a signal is sent to stop the motion of thespout can vary considerably depending upon temperature and otherenvironmental conditions. In extreme cold, lubricants tend to be thickerand the brake more effective, thus causing quicker stopping of thespout. When temperatures are very warm, lubricants are thinner and thebrake is less effective, allowing a larger amount of coasting after sometypes of motors are inactivated.

Accordingly, the position proof window and the sensing of the positionproof window assure that the grain distribution spout is properlypositioned to accurately deliver grain to the desired receiving duct.

The large mass involved in moving a 1200 to 1500 pound graindistribution spout, places a good deal of strain on spockets and chainsthat are used to move the spout, particularly in pendulum style graindistributors. If the spockets or chains fail, the spout drops toward avertical position and can misdirect the flow of grain. As discussedabove, the financial consequences of misdirecting and mixing forexample, corn and soy beans can be significant.

The grain distribution spout can be moved from its desired distributionposition by a discontinuity of the grain flow. For example, a frozenlump of grain may cause the spout to shift position. In addition, anelectrician or other maintenance worker can accidentally move the graindistribution spout and cause a loss of calibration. The grain may thenbe misdirected into an adjacent discharge position causing anundesirable mixing of grain types and attendant loss of grain purity andvalue.

SUMMARY OF THE INVENTION

The present invention solves many of the above discussed problems. Thepresent invention facilitates absolute spout positioning so that eachduct which is uniquely identified is accurately accessed. A one-timeautomated set-up procedure allows the grain distributor of the presentinvention to learn all parameters of the distributor and even correctsfor reverse motor wiring. The grain distributor of the present inventionrequires no mechanical adjustment. The present invention furtherfacilitates rapid closest path positioning of the spout to any duct. Alldistributor parameters in the present invention are saved innon-volatile memory in case of power loss. After a power loss, the graindistributor of the present invention verifies spout position when poweris restored.

In accordance with the present invention, a housing contains adistribution spout that is rotated by a drive motor among a number ofdrive positions at each receiving duct. In an example embodiment, acontrol wheel connected to the spout rotates with the spout to aselected discharge position. The control wheel presents a plurality ofcode clusters that can be sensed. Each of the code clusters isassociated with a discharge position. Each code cluster has a uniqueseries of data digits and a series of sequencing digits adjacent thedata digits. The data digits and the sequencing digits are serially readas the digits passed by a sensor that includes a first sensor unit and asecond sensor unit. The sensor units are operably connected to a controlprocessor for identifying the position of the spout. The controlprocessor allows the data digits to be read only when a sequencing digitis also being read.

When it is desired to access a particular discharge position of thespout, the control processor operates the drive motor until the datadigits corresponding to the desired discharge position have been sensedby the sensors. The control processor then continues to operate thedrive motor for a predetermined period of time and stops the motor atwhich point the discharge spout should be properly positioned at theselected discharge position. Each coded cluster is associated with aproof window. The proof window is positioned on a coded portion to beconfronting the sensor when the discharge spout has been properlypositioned at the discharge position. The proof window is structured sothat it does not include a sequencing digit as do the data digits. Inthis way, the control processor can always be sure that the wheel andthus the distribution spout is sensing the proof window and not a dataslot because the proof window is positioned so that no associatedsequencing digit exists.

In accordance with the present invention, the control processor isprogrammed to perform a one-time automated set-up procedure after thegrain distributor of the present invention is installed.

The grain distributor of the present invention includes an inductivesensor to sense the code clusters and the proof windows. The codeclusters are structured such that each data position includes a sequencedigit which is always present and a data digit which can be present ornot present. The sequence digit is sensed by a first sensor while thedata digit is sensed by a second sensor. The proof window is only sensedby the second sensor and there is no associated sequence digit.

The controller first rotates the distribution spout to identify how manycode clusters exist and, thus, the number of positions to which thespout may be pivoted. For example, the controller commands rotation ofthe spout and identifies code clusters eleven, twelve and thirteen insequence indicating that the spout is rotating in a forward direction.The controller continues rotation until all of the code clustersindicating spout positions have been sensed and recorded.

The controller then rotates the distribution spout until the first andsecond sensors of the inductive sensor detect the first code cluster.Rotation continues until the second sensor senses the first edge of thefirst proof window. A time counter entry is recorded upon the sensing ofthe first edge of the proof window. The counter then runs until thesecond edge of the proof window is sensed and the counter is stopped orthe time is recorded. The recorded time from the counter to transit fromthe first edge of the proof window to the second edge of the proofwindow is halved to identify the center of the proof window. The halfvalue is then saved and associated with the center of the first proofwindow. This process may, if desired, continue for each of the pluralityof code clusters and proof windows until all of the code clusters andproof windows have been read. If the precision of manufacturing is goodfor the positioning of the spout and the code clusters it may besufficient to self program only a single code cluster and spout positionand rely on the known spacing of the further code clusters foradditional code clusters and spout positions. This procedure may berepeated for each proof window associated with each desired dischargeposition of the grain distributor.

In one example embodiment, the controller is programmed to predict whatthe next expected code cluster and proof window should be. If thepredicted event does not occur the controller may be programmed toreverse the direction of rotation of the spout until a blank spot whereno code cluster elements are present and then to proceed forward againto accurately identify the code clusters encountered.

The identified mid-point values of each proof window are saved in anon-volatile long term memory and used throughout the life of the graindistributor to ascertain accurate positioning of the grain distributionspout. According to one embodiment of the present invention, the motoris a synchronous motor, the speed of which can be controlled bycontrolling the frequency of the alternating current that is supplied tothe motor. The synchronous motor can be precisely started and stopped bycontrol of the frequency of the electricity supplied to the motor. Inone example embodiment, the frequency may be controlled by avariable-frequency drive operably coupled to the motor. The applicationof a variable-frequency drive has the advantage of eliminating allmechanical switches and relays from the vicinity of the grain. Thiseliminates wearing parts from the system that occur because the switchesare operated repeatedly and eliminates arcing that may occur with theoperation of relays and mechanical switches.

Another advantage of the use of a variable-frequency drive is improvedprecision of control as compared to the use of a brake motor. Thepositioning of the distributor spout is more repeatable with the use ofa variable-frequency drive in concert with a synchronous motor. Further,with variable-frequency drive stopping of motion of the grain spout isrepeatable regardless of load on the spout and whether the load ispositive or negative.

According to another example embodiment of the invention, once the spoutis positioned to deliver grain to a particular port the proof window ismonitored continuously. If the proof window is found to be out ofposition, indicating that the spout is out of position error messagesare sent to the control console and various actions may be initiated bythe controller including automatically stopping the flow of grain to thespout.

The invention also includes a grain distributor having a controlprocessor programmed to perform the above discussed method.

The present invention also includes a computer readable data carriercomprising programming to perform the herein described method and tosupport operation of the herein described device.

According to another example embodiment of the invention, the computerimplemented method of calibrating a grain distributor for electricallycontrolled operation, further includes identifying the type of graindistributor that is being calibrated and if the grain distributor is anon-circular grain distributor that has end positions at which transitof the distribution spout must stop, identifying those end positions andpreventing the spout from striking the end of the grain distributor.Grain distributors come in two basic types, circular distributors inwhich the spout may transit a circle in either direction and rotatecompletely around the circle and noncircular distributors that have endsat which the spout must reverse travel direction. Examples of circulardistributors are depicted in FIGS. 1-3. Noncircular grain distributorsthat have two ends are depicted for example in FIGS. 10 and 11.Non-circular two end distributors may include pendulum or swing typedistributors as well as distributors that complete an arc but not entirecircle. Some of these distributors are known as flatback distributors.

After a new grain distributor or grain distributors are installed, theyundergo a self-programming process according to the invention. Theinvention permits people less skilled in the design and understanding ofgrain distributors such as an electrician to initiate the initialself-programming of the distributor in accordance with the invention.

When the self-programming process is initiated after installation, thedistributor spout may be in any position. That is, the spout may belocated such that the sensors are in the midst of a code cluster or thespout may be located such that the sensors are between two codeclusters. In accordance with the invention, the self-programming processfirst identifies whether the distributor is a circular distributor orone that has two ends at which the spout must stop. Second, theself-programming process identifies whether the distributor is one thathas five digit code clusters or six digit code clusters. Five digitalcode clusters are sufficient for circular distributors that have up to30 ducts. For circular distributors having more than 30 ducts, six digitcode clusters are used. Six digit code clusters need not be used for alldistributors. The use of six digit code clusters may be limited forsmaller distributors because of space constraints. Because of the needto identify the ends of distributors that have end positions at whichthe spout must reverse direction, noncircular, direction reversingdistributors may require six digits code clusters if they have over 18ducts.

Upon initiation, the program first identifies whether the sensorsassociated with the spout are located between two code clusters orwithin a code cluster. This is accomplished by advancing the spout untila complete or partial code cluster is read. If a complete code clusteris read, the control processor operating the inventive self-programmingmakes a record of the number represented by the complete code clusterread. If only a partial code cluster is read, the control processorcommands the spout to reverse direction until the sensors are out of thecode cluster and therefore between two code clusters. The spout is thenadvanced so that the entire code cluster is read. This also providesinformation as to whether the code cluster is a five digit or six digitcode cluster which can be saved. A decision is also made as to whetherthe code cluster that has been read is a possible end code cluster thatwould require reversal of the direction of the motion of the spout.

If the code cluster is a possible value of an end code cluster, then thespout is commanded to reverse direction and to read the value of theprior code cluster. In accordance with the invention, end codes clustersare unique, first because they are designed to read different numericalvalues when they are read in the left to right direction as opposed tobeing read in the right to left direction. In other words they lacksymmetry. End code clusters are unique, secondly, because they are largenumbers relative to the numerical values of the other code clusters inthe distributor.

This application discusses example end code clusters for five digit codeclusters, though similar principles can be applied to six digit codeclusters or to code clusters having more than six digits. One example afive digit end code cluster has numerical values of 19 and 25 dependingupon which direction the code cluster is read. The binary values of thefive positions in the five digit code cluster are 1, 2, 4, 8 and 16. Ifthe first, second and fifth digits are marked in the code cluster whenread in a first direction, the value of the code cluster will be 19because those digits are 1, 2 and 16. 1+2+16=19. If the same codecluster is read in the opposite direction, its value will be 25 becausethe digits that are marked are read as 1, 8 and 16, 16+8+1=25.Accordingly, if the algorithm encounters a code cluster having a valueof 19 when read in a first direction and 25 when read in the oppositedirection, the code cluster is, potentially, an end code cluster. Itcould also be a code cluster representing the nineteenth duct in acircular distributor having more than 18 ducts. Another example end codecluster has a value of 29 and 23. In this case again, a five digit codecluster has four data digits when read from left to right which are thefirst, third, fourth and fifth positions. When read in a firstdirection, the binary digits have the values of 1, 4, 8 and 16.1+4+8+16=29. When read in a second direction, the digits have the valuesof 1, 2, 4 and 16. 1+2+4+16=23. Thus, this code combination is apotential end code. It is also possible that this code cluster is the29^(th) code cluster in a circular distributor. According to theinvention, once a code cluster is read that is a potential end code, thealgorithm commands the spout to stop after reading that code cluster andto reverse direction to read the prior code cluster, if the prior codecluster is not a sequential value to the possible end code cluster read,the algorithm determines that this code cluster is an end code clusterand commits that information to memory.

Also, note that a distributor having end codes has a total number ofcodes including the two end codes that one less than the total number ofducts that the distributor has. For example, a non-circular distributorhaving four ducts has a total of three codes including two end codes anda single intervening code. An example sequence of codes from left toright is a first end code followed by a code having a value of threefollowed by a second end code. The first end code used to position thespout at the first duct and the second duct depending on the directionin which it is read. Each duct has an associated proof window. Thus, atwo ended distributor according to the invention having four ducts hasfour proof windows and three total codes including two end codes and oneintervening code.

According to the invention, end code clusters may have three qualities,their code clusters have a different numerical value when read right toleft as compared to being read left to right, they are non-sequential innumerical value with their adjacent code cluster and they are relativelylarge numbers as compared to the rest of the code clusters for thedistributor.

Once a verified end code cluster has been identified, the algorithm thencommands the spout to reverse direction to read all of the sequentialend code clusters that exist between the two end code clusters and toidentify the end code cluster at the opposite end of the graindistributor.

If no end code clusters are identified, the algorithm then commits tomemory the fact that the distributor in question is a circulardistributor. In a circular distributor it is possible, in accordancewith the invention, to program the operation of the circular distributorso that the spout will take the shortest route around the circle to thenext desired grain receiving duct based on the numerical values of thecode clusters. This shortest route programming is also utilized innon-circular distributors.

In an example embodiment of the invention, let us assume a flatbacknon-circular distributor having 18 ducts. This distributor then has twoducts, the first and the 18^(th) that are identified by end codes and 16intervening ducts that are identified by code clusters having values of3-17. Let us also assume that after the distributor is installed, thespout is positioned so that the sensor is in the midst of the first endcode cluster. According to the invention, the spout is commanded toadvance and the sensor reads a partial code cluster. At this position,the algorithm commands the spout to stop and reverse direction. Thespout then reads all five digits of the end code cluster and determinesthe value of 25 for the five digits. The spout is then commanded toreverse direction again to read the end code cluster again and reads thevalue of 19 because of the reversed direction. When this has been done,the end 19-25 code cluster is identified as a possible end code cluster.The spout is then commanded to advance again to read the next codecluster which is number 3. At this point, the algorithm has confirmedthat the first cluster read was in fact an end code cluster having thevalue of 19-25.

The fact that the next code cluster has a non sequential and smallervalue of 3, confirms that this is an end code cluster and it iscommitted to memory that this is a grain distributor that has two ends.The spout then advances and reads the ensuing and code clusters insequence identifying spout position 2, 3, 4, 5 and so on until itreaches spout position 17. The next code cluster read will also be anend code cluster which will have a value of 23. Because this end codecluster is out of sequence having a value of 23 following 17, it willalso be identified as an end code cluster and the algorithm will thencommit to memory the fact that this is an end code position of thedistributor. Once this procedure has been completed a single time foreach distributor within the system, the information is memorized and thedistributors may be operated without any need for operator programmingof the initial location of the spout and the grain receiving ducts.

In another embodiment of the invention the control processor is furtherprogrammed to identify the code clusters having sequential numericalvalues starting adjacent to the first end code cluster until a secondprobable end code cluster is identified and confirmed thus identifyingall code clusters associated with the distributor.

In another embodiment of the invention the control processor is furtherprogrammed to memorize a numerical value of the first code clusterencountered by the sensor and to continue counting the code clusters insequence until the numerical value of the first code cluster isencountered again thus confirming that the distributor is a circulardistributor and identifying the total number of ducts in thedistributor.

In another embodiment of the invention the control processor is furtherprogrammed to identify whether a first binary digit in the code clustersalternates thereby determining that the spout is moving in a logicalforward direction or if the first binary digit does not alternatedetermining that the spout is moving in a logical backward direction.

In another embodiment of the invention the control processor is furtherprogrammed to repeat identifying whether the first binary digit in thecode clusters alternates thereby determining that the spout is moving inthe logical forward direction or if the first binary digit does notalternate determining that the spout is moving in the logical backwarddirection three times.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an embodiment of the invention with acylindrical housing, two distribution ducts, and circularly arrangedreceiving ducts;

FIG. 2 is a partial sectional elevational view of the embodiment of FIG.1;

FIG. 3 is a top view of the embodiment of FIG. 1 with parts removed toreveal the inductive sensors and the annular control wheel with embeddedcode clusters according to an embodiment of the invention;

FIG. 4 is a cross-sectional detail of a portion of an annular ring witha support roller guide, inductive sensors, and a double-wide drive chainaccording to an embodiment of the invention;

FIG. 5 is a sectional view taken along section 5-5 of FIG. 2 of aportion of the control wheel and the drive sprocket with the double widechain engaged according to an embodiment of the invention;

FIG. 6 is a sectional view taken along section 6-6 of FIG. 2 depicting abottom view of the control wheel with the code clusters, the drivesprockets, the drive chain, and the inductive sensors;

FIG. 7 is a cross-section detail view taken along section 7-7 of FIG. 6depicting sensor units of an inductive sensor and two digits of a codecluster according to an embodiment of the invention;

FIG. 8 is a diagrammatic bottom view of the control wheel showing thearrangement of the inductive sensors with respect to the code clusterand showing the sensors connected to the control processor according toan embodiment of the invention;

FIG. 9 is a diagrammatic view depicting both inductive sensors and thedrive motors connected to the control processor according to anembodiment of the invention;

FIG. 10 is a front elevational view of an alternate embodiment of agrain distribution apparatus configured in a “swing set” arrangement,and with the coded portion arranged on an arcuate strip according to anembodiment of the invention;

FIG. 11 is a top view of the embodiment of FIG. 10 with the inductivesensors attached to the pendant distribution duct and the arcuate stripattached to the side of the housing according to an embodiment of theinvention;

FIG. 12 is a diagrammatic view of a control processor according to anembodiment of the invention; and

FIG. 13 is a flowchart partially depicting a calibration methodaccording to an embodiment of the invention.

FIG. 14 is another flowchart partially depicting a calibration methodaccording to an embodiment of the invention.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2, grain distribution apparatus 20 includessubstantially cylindrical housing 22 having open interior 23, withinwhich is contained a pivotal inner distribution spout 24 surrounded bypivotable annular distribution spout 26. Inner distribution spout 24 isrotated by drive means 28. Similarly, annular distribution spout 26 isrotated by second drive means 30. Position sensing of inner distributionspout 24 is provided by inductive sensor 32 and similarly secondinductive sensor 34 is provided for annular distribution spout 26.

A plurality of receiving ducts 36 extend downwardly from housing 22.When used herein, “pivotal” is intended to be broadly construed andincludes “rotatable” within its meaning.

Grain distribution apparatus 20, as shown in FIGS. 1 and 2, isconnectable to two grain sources, not shown, by way of two flanges 38,40 which extend from top 42 of housing 22 and connect respectively toreceiving end 44 of inner distribution spout 24 and receiving end 46 ofannular distribution spout 26. Connecting duct work 47, 48, connectsflanges 38, 40 to the two grain sources. Receiving ducts 36 similarlyinclude flanges 49 for attachment of connecting duct work 50, shown inphantom lines, for transporting the distributed grain to selected bins,not shown, or elsewhere as desired. Housing 22 and duct work 47, 48, 50may be fabricated from sheet metal or plate stock by conventional means.

Referring to FIG. 2, inner distribution spout 24 includes receiving end44, pivoting portion 54, and discharge end 56. Pivoting portion 54 isrotatably supported by shaft 58 which is coaxial with housing 22 andfurther supported by angular bracing 60 which connects between thedischarge end 56 and the shaft 58. Shaft 58 is rotatably mounted onbearing block 62 which is attached to support plate 64 located at bottom66 of housing 22. Pivoting portion 54 may be axially constrained byinner wall 68 of annular distribution spout 26.

Annular distribution spout 26 also pivots in a rotational sense and isrotatably supported by attachment to annular control wheel 72 locatedadjacent to top 44 of housing 22. Annular control wheel 72 isring-shaped and is supported by a plurality of support roller guides 74attached to and extending downwardly from top 44 of housing 22 as shownin FIG. 2 and may be generally positioned as shown in FIG. 3. Annulardistribution spout 26 includes receiving end 46, rotatable portion 75attached annular control wheel 72, and discharge end 76.

Discharge end 56 of inner distribution spout 24 and discharge end 76 ofannular distribution spout 26 are thus independently rotatable withinhousing 22 to face receiving ducts 36. Each receiving duct 36 includesreceiving portion 77 into which grain is poured from discharge ends 56,76. Each pivotal or rotational position of discharge ends 46, 76 whendirected into receiving portion 77 of each receiving duct 36 defines apivotal or rotational discharge position.

Drive means 28, 30 for inner distribution spout 24 and annulardistribution spout 26, are generally shown in FIG. 2 and have portionsshown in greater detail in FIGS. 3, 4, 5 and 6. Referring first to drivemeans 28 for inner distribution spout 24, motor 78 is mounted externallyto housing 22 and connects to shaft 79 in open interior 23 of housing 22which connects to right angle drive 80 mounted to support plate 64.Shaft 82 extends out of right angle drive 80 and connects to drivesprocket 84. Drive sprocket 84 is engaged to double-wide chain 86 whichextends around and is engaged with control wheel 88 configured as adriven sprocket. Control wheel 88 is fixed to control shaft 58 wherebyrotation of control wheel 88 also rotates shaft 58 and thus causespivoting portion 54, and discharge end 56 of inner distribution spout 24to rotate among the various receiving portions 77 of receiving ducts 36.

Drive means 30 has a similar configuration with motor 90 mountedexternal to housing 22 and directly connected to right angle drive 92.Extending downward from right angle drive 92 is a shaft and drivesprocket 94 which is engaged to a second double-wide chain 96.Double-wide chain 96 is simultaneously engaged with control wheel 72which is also configured as a sprocket.

Motors 78, 90, as shown, are conventional electric motors howeverhydraulic or even pneumatic motors may also be suitable. Additionally,the drive means 28 and second drive means 30 may also include a powertake-off arrangement rather than utilizing a direct drive motor. Aone-half horsepower three-phase electric motor with an electromechanicalbrake is generally suitable for this application. Also, suitable aresynchronous motors having a variable frequency drive. Thus, the speed ofthe synchronous motor is controlled by the frequency of its electricalsupply.

Referring specifically to FIG. 3, a top plan view of grain distributionapparatus 20 is depicted with top 42 of housing 22 removed, disclosingthe positioning and configuration of annular control wheel 72. Motor 92and support roller guides 74 are shown suitably positioned, although itshould be noted that motor 92 and roller guides 74 are attached to andsupported by top 52 and top 52 has been removed in this view. Flanges38, 40 and discharge ends 56, 76 for inner distribution spout 24 andannular distribution spout 26, are depicted in this view. Rotatableportion 75 of annular distribution spout 26 funnels down towarddischarge end 76. Double-wide chain 96 is depicted encompassing andengaged with periphery 98 of control wheel 72.

FIGS. 4 and 5 depict details of the engagement by double-wide chain 96with both control wheel 72 and drive sprocket 94. Control wheel 72 has aperiphery 98 with a plurality of teeth 100 which engage chain 96. FIG. 4depicts a cross-sectional view of chain 96 and control wheel 72.Double-wide roller chain 96 is conventional in nature and includes aplurality of rollers 102 and pins 104 with pairs of rollers 102connected by roller link plates 106 and pairs of pins 104 connected bypin connecting plates 108. FIG. 4 also depicts support roller guide 74.Each guide 74 includes vertically mounted roller 112 and horizontallymounted roller 114 which engage lower surface 116 and inside edgesurface 118 of control wheel 72 for supporting and guiding the rotationof control wheel 72 and correspondingly rotatable portion 75 and end 76of annular distribution spout 26.

Referring to FIGS. 4 and 5, double wide chain 96 includes first portion118.5 and a second portion 119.5 divided by center links 119. Firstportion 118.5 is engaged by drive sprocket 94 (not shown in FIG. 4), andsecond portion 119.5 engages control wheels 88, 72. The sprocket androller chain may be appropriately sized as best seen in FIG. 4 so thatthe sprockets fit constrictively within the respective portion of chain96. The constrictive fit minimizes movement of the chain on the controlwheel and thus minimizes chain and sprocket wear.

FIG. 6 depicts a partial sectional view taken along section line 6-6 ofFIG. 2 showing the control wheel 88 configured as a driven sprocketwhich rotates the pivoting portion 54 and discharge end 56 of innerdistribution spout 24. Control wheel 88 has periphery 118 which has aplurality of teeth 120 for engaging double-wide chain 86. Drive sprocket84 has similarly spaced teeth 121 relative to control wheel 88. Bothcontrol wheel 88 and drive sprocket 84 are engaged with double-widedrive chain 86 simultaneously at the region denoted by the numeral121.5.

Referring again to FIG. 2, sensing means 32, 34 for sensing therotational position of inner distribution spout 24 and annulardistribution spout 26, are depicted. Sensing means 32 for innerdistribution spout 24 includes inductive sensor 122 and control wheel88. Inductive sensor 122 is suitably attached to support plate 64 andextends upwardly to confront control wheel 88. Similarly, sensing means34 for the annular distribution spout 26 includes inductive sensor 124and control wheel 72. Inductive sensor 124 extends downwardly from top44 of housing 22 to confront control wheel 72.

Referring to FIGS. 3, 4, 5 and 6, the elements of sensing means 32, 34are depicted in greater detail. FIG. 3 depicts the annular control wheel72 which includes coded portion 128 that extends circularly aroundannular control wheel 72. Within coded portion 128 there are codeclusters 130, each of which are positioned for and correspond to arotational discharge position of annular distribution spout 26.Inductive sensor 124 is oriented toward control wheel 72 and controlwheel 72 is configured so that as control wheel 72 is rotated, inductivesensor 124 is maintained over coded portion 128 of wheel 72 and codeclusters 130 rotate past the sensors 124. FIG. 4 depicts details ofinductive sensor 124 confronting control wheel 72 of annulardistribution spout 26. Inductive sensor 124 is includes first sensorunit 132 and second sensor unit 134 with lead wires 136, 138 extendingfrom each sensor unit 132, 134 through top 42 and out of housing 22.Sensor units 132, 134 are contained within housing 140 formed of asuitable nonferrous material such as very high molecular weight (VHMW)plastic. Two screws 141, one which is shown in FIG. 4, in conjunctionwith springs 142 may be utilized to maintain sensor housing 140 incontact with control wheel 72. An example suitable inductive sensor ismodel Bi 2-P12-80 available from Turck, Inc., 3000 Campus Drive,Minneapolis, Minn. 55441.

FIG. 5 shows a detail of two code clusters 130 on annular control wheel72. Each code cluster 130 in this example includes five pairs 143 ofdigits and identifies a particular discharge position of the spout. Thefive pairs 143 of digits of each code cluster 130 include outer datadigit 144 and inner sequencing digit 145. Each discharge position alsopresents position proof window 145.1 including a pair of digits 145.5including inner first digit 145.6 and outer second digit 145.7. Positionproof digits 145.5 are slightly distanced from the other pairs of digits143 and are positioned to be in alignment with sensor 124 when dischargespout 26 is appropriately aligned with the discharge positioncorresponding to any particular code cluster.

Digits 144, 145, 145.6, 145.7 are binary digits where a hole in thecoded portion equates to “1” and no metal removed equates to “0”. Thatis, the presence of the base material of the coded wheel constitutes a“0”. For this example embodiment sequencing digits 145 in each codecluster always have the value of “1”. There are no “0” value sequencingdigits. The presence of a sequencing digit 145 designates the presenceof an adjacent outer data digit 144. Inner position proof digit 145.6 ispositioned to be read by the first data digit sensor unit 132 and has abinary value of “1”. Outer position proof digit 145.7 is positioned tobe read by second or sequencing digit sensor unit 134 and in thisembodiment has the binary value of “0”. Significantly, position proofwindows 145.1 are the only digit pairs on the coded portions in whichthe first sensor unit 132 reads a “1” and the second sensor unit 134reads a “0”

The digits 144, 145, 145.6, 145.7 may be formed by cutting appropriatelysized holes into coded portion 128 of control wheel 72 or by any similartechnique in which the “0” and “1” digits are differentiated as sensedby the sensor.

Referring to FIG. 4, the cross-section of the annular control wheel 72shows the two “1” digits 144, 145 of a code cluster positionedimmediately below the sensor units 132, 134 of the inductive sensor 124.In this example, the more inwardly positioned first sensor unit 132 isutilized for sensing sequencing digits 145 and the more peripherallypositioned second sensor unit 134 is utilized for sensing data digits144. Digits 144, 145, as shown when designating a “1” can be filled witha nonferrous material where the ferrous material of control wheel 72 hasbeen cut away. This may minimize the likelihood of foreign matterlodging in digits 144, 145. The digits 144, 145, when representing “0”,have no metal removed.

Referring to FIGS. 6, 7, and 8, details of sensing means 32 for innerdistribution spout 24 are depicted. Inductive sensing means 32 includesinductive sensor 122 and control wheel 88. Inductive sensor 122 includesfirst sensor unit 146 and second sensor unit 148 enclosed in nonferroushousing 150. Control wheel 88 for inner distribution spout 24 also hascoded portion 154 which includes code clusters 156 and associatedposition proof windows 145.1 positioned in a circular arrangement aroundcontrol wheel 88. In this example embodiment, inductive sensor 122 ispositioned on support plate 64, and control wheel 88 is configured sothat two sensor units 146, 148 are positioned to sense code clusters 156as control wheel 88 is rotated.

Note that control wheels 72, 88 of FIGS. 3 and 6 present data digits 155more inwardly positioned and FIGS. 4, 5, 7, and 8 present the sequencingdigits 157 more inwardly positioned on the control wheels. Eitherpositioning is suitable.

FIG. 7 is a detail drawing of inductive sensor 122 confronting controlwheel 88. Two digits 155, 157, one above each sensor unit 146, 148 arepositioned immediately above inductive sensor 122. Digits 155, 157 asshown, each representing a “1” constitute apertures in control wheel 88and are not filled with material in this embodiment.

FIG. 8 is a bottom view of inductive sensor 122 with two sensor units146, 148 positioned at two digits 155, 157 with sensor units 146, 148electrically connected to control processor 158 by lead wires 160, 162.Each code cluster 156 in this example includes five pairs of digits 163.Each digit 163 includes outer data digit 155 and inner sequencing digit157. The more inwardly positioned sensor unit 148 is utilized forsensing sequencing digits 157 and more peripherally positioned sensorunit 146 is utilized for sensing data digits.

Referring to FIG. 9, a diagrammatic view of two inductive sensors 122,124 is shown including individual sensor units 132, 134, 146, 148electrically connected to control processor 158. Additionally, theelectric motors 78 and 90 also are electrically controlled by controlprocessor 158.

Referring to FIGS. 10 and 11, an additional alternative exampleembodiment of the apparatus is shown in which housing 164 is somewhatpie-shaped and includes arcuate lower portion 166. This type of graindistribution apparatus 20 is known in the industry as a “swing set” or“pendulum” distributor and is generally indicated by numeral 168. FIG.10 has a portion of the front of the housing broken away to revealarcuate control strip 170 which includes coded portion 172 with codeclusters 174. Swing set style distributor 168 has two swingingdistribution spouts 176, 178 which pivot by suitable means at top 180 ofhousing 164. Swinging distributor spouts 176, 178 are movable by way ofchains 182 one of which is shown in FIGS. 10 and 11. Chain 182 extendsbetween sprockets 184, 186 which are respectively attached to additionalsprockets 188, 190. Chain 182 extends in an arcuate manner by way ofguides 192 which are attached to housing 164. Swinging distribution duct176 is anchored to chain 182 by way of bracket 194. Positioned onswinging distribution duct 176 is inductive sensor 196, as depicted inFIG. 11, which confronts coded portion 172 of control strip 170. Codeclusters may be of similar design as described in other embodiments.Rotation of additional sprockets 190, 188 by suitable means, such aselectric motors swing distribution duct 176 along arcuate lower portion166 whereby any desired receiving duct may be selected. Similar to otherembodiments, the distribution spout includes receiving end 202, pivotingportion 204, and discharge end 206.

Referring to FIG. 12, in a diagrammatic representation of a suitableconfiguration of control processor 158, is shown. Control processorcircuitry is conventional and comprises signal conditioning circuitry207, programmable peripheral interface 208, central processing unit 210,program memory 212, data memory 214, keyboard/display 216, RS-232converter 218, and solid state relays 220 for controlling the motors.Suitable design and programming details are apparent to those ordinarilyskilled in the art.

In operation, referring to FIG. 2, grain distribution apparatus 20 isconnected to grain sources by connecting duct work 47, 48 and receivingducts 36 are connected to desired bins or other grain destinations. Withsuitable programming in place in control processor 158, a specificreceiving duct is selected for either inner distribution spout 24 orannular distribution spout 26. The appropriate motor 78, 90 is activatedby control processor 158 to rotate either annular control wheel 72 orcontrol wheel 88 for inner distribution spout 24. For purposes of thisexplanation of operation annular control wheel 72 will be described.With the activation of motor 90, sprocket and shaft 94 rotate and, byway of their engagement with the double-wide chain 96 which is engagedwith annular control wheel 72, annular control wheel 72 also rotates.Connected to and extending downward from the annular control wheel 72 ispivotal or rotatable portion 75 and discharge end 76.

With five data digits in each code cluster 130, 156, 174, a uniquenumeric value between one (1) and thirty-two (32) has been assigned toeach of the code clusters to correspond to a rotational dischargeposition. This data is stored in control processor 158 by the selfprogramming method disclosed herein.

Referring to FIG. 6, each code cluster 156 shown in FIG. 6 is comprisedof five sequencing digits 157 and five data digits 155. Each digitrepresents the binary numbers “0” or “1” by way of the presence orabsence of metal respectively. The “0” digits are simply comprised ofthe base material of the control wheel 88. As control wheel 88, shown inFIGS. 2, 3, 4, and 5, moves past inductive sensor 122, second sensorunit 148 senses when sequencing digit 157 is in place below theinductive sensor 122. The first or data digit sensor unit 146 becomesoperative by way of the control processor 158 to then read paired binarydata digit 155 which is then present under sensor unit 146. Data digits155 cause sensor units to generate a signal comprising a pulsecorresponding to a “1” and no pulse for an “0”. The signal istransmitted to control processor 158.

The five data digits 155 in a code cluster 156 have an assigned binaryvalue of 1, 2, 4, 8, and 16 respectively. Data digits 144 are read orsensed in sequence and are only read when a sequencing digit 145, whichis always a “1”, is sensed. Control processor 158 then arithmeticallyadds the assigned values of the data digits read as “1” to define theaddress or the positioning of control wheel 72 and thus the distributionspout based on code cluster 156 that has just passed under inductivesensor 122. Significantly each code cluster 156 has a unique numericvalue which is conventionally stored in control processor 158. Whencontrol processor 158 determines that code cluster 156 with the assignednumeric value for the rotational position that it was searching for haspassed under inductive sensor 122, control processor 158 stops motor 90driving control wheel 72. At this point discharge end 56 of spout 24should be in perfect alignment in discharge position with the desiredreceiving portion 77 of the selected receiving duct 36. Controlprocessor 158 may be configured and code clusters 156 positioned toallow the motor 90 to operate for a predetermined amount of time ratherthan immediately stopping.

In such an alignment position, code cluster 130, 156, 174 correspondingto the selected discharge position will have moved past sensor 32 andsensor 32 will now be stopped over position proof window 145.1. Controlprocessor 158 will suitably acknowledge the proper positioning oractivate an alarm if the discharge end or spout is not properlypositioned. The width of position proof window 145.1 may be suitablysized to accommodate any acceptable range of positioning of thedischarge end of the spout at receiving portion 77. Position proofwindows 145.1 thus provide a window of acceptable placement positions.

Moreover, position proof windows 145.1 may monitor the continued properpositioning of the discharge end or spout during a grain transfer.

The grain source is opened allowing the grain to pass into receiving end46 and into pivoting portion 75. Pivotal portion 75 of annulardistribution spout 26 operates as a funnel to direct the grain aroundinner distribution spout 24 to discharge end 76. Discharge end 76 thendirects grain to open receiving portion 77 of receiving duct 36.

Inner distribution spout 24 operates in a like manner. In the embodimentshown in FIGS. 1 and 2, positions for both inner distribution spout 24and annular distribution spout 26 may be separately selected and thespouts rotate independently of each other.

Notably, the digits and code clusters may be formed from any suitablemeans in which a sensible code cluster as sensed by the selected sensorare produced. This may take the form of adding additional metal or metalof a different inductivity where inductive sensors are used.

Additionally, different sensors other than inductive are contemplatedand may be utilized with the invention. Conventional photoelectricsensing means, capacitive sensing means, and magnetic sensing means arehighly suitable for the binary code system just described. In theembodiments described in detail above the digits are inductivelydifferentiated and the inductive sensor units are the sensors. In otherembodiments alternate digits constitute other known ways of providingdifferentiations at the coded portions which would be sensed by othersuitable sensors. These include mechanical detents or fingers definingthe code clusters which actuate mechanical switches constituting thesensors. Digits with differentiated light absorption characteristics canbe used in conjunction with photoelectric or similar sensors. Magnetscan be utilized for the “1” digits with reed switches or other magneticsensing devices as the sensors.

It is further understood that innumerable variations of the codingsystem are available in which unique signals are generated for variousrotational positions. Moreover, the code clusters may be positioned atmore rotational positions than just the discharge positions. Forexample, unique code clusters may be placed at every 10 degrees ofrotation.

Significantly, the two inductive sensors and most other suitable sensorsrequire a minimal number of leads to the control processor, typicallytwo from each sensor unit.

The embodiment depicted in FIGS. 10 and 11 operate in a similar fashionexcept that arcuate control strip 170 which contains coded portion 172with code clusters 174 is attached to housing 164 and swingabledistribution duct 176 caries inductive sensor 196 attached to it.Inductive sensor 196 then moves along control strip 170 as swingingdistribution duct 176 is swung by way of chain 182.

Moreover, the embodiments disclosed utilize a coded portion that isfixed to the pivoting spout that moves past a fixed sensor. It is alsocontemplated that sensors may be fixed to the spout to move past a codedportion fixed to the housing. Thus where it is stated herein that thecoded portion moves with respect to the sensor, either the sensor or thecoded portion may be fixed.

FIG. 13 is a flow chart depicting a calibration method according to anembodiment of the invention. This procedure need be performed only onceupon initial installation of the grain distributor apparatus 20 inaccordance with the invention.

In an initial step 222, central processing unit 210 is programmed tocommand the rotation of control wheel 88. Rotation of control wheel 88causes control wheel 88 to pass by inductive sensor 32 and secondinductive sensor 34 which then read code clusters 130. All of codeclusters 130 are read to identify the number and position of receivingportions 77.

In step 224, the digital signals represented by code clusters 130 aredetected by first sensor unit 132 and second sensor unit 134. Thesignals are transmitted to central processing unit 210 and recorded indata memory 214 in step 226.

As control wheel 88 rotates, the first edge of proof window 145.1 isdetected, the second sensor unit 134. A first time value associated withthe first edge when the 145.1 is recorded in step 230.

In step 232 as control wheel 88 continues to rotate, the second edge ofproof window 145.1 is detected by second sensor unit 134. Upon detectionof the second edge of proof window 145.1 in step 234, the second timevalue associated with the second edge of proof window 145.1 is recorded.

In step 236, the processor performed a calculation calculating amid-point value between the first and second time values indicating thefirst edge and second edge of the proof window 145.1. In step 238, thismid-point value is then associated with the recorded digital signalidentifying the spout position.

The example procedure is then repeated for each position of innerdistribution spout 24 associated with each of receiving ducts 36 andassociated code cluster 130. These values have been stored in computermemory and accessed for future positioning of the spout based oncommands from the central processing unit 210.

According to another example embodiment of the invention, the computerimplemented method of calibrating a grain distributor for electricallycontrolled operation, further includes identifying the type of graindistributor that is being calibrated and if the grain distributor is anon-circular grain distributor that has end positions at which transitof the distribution spout must stop, identifying those end positions andpreventing the spout from striking the end of the grain distributor.Grain distributors come in two basic types, circular distributors inwhich the spout may transit a circle in either direction and rotatecompletely around the circle and noncircular distributors that have endsat which the spout must reverse travel direction. Examples of circulardistributors are depicted in FIGS. 1-3. Noncircular grain distributorsthat have two ends are depicted for example in FIGS. 10 and 11.Non-circular two end distributors may include pendulum or swing typedistributors as well as distributors that complete an arc but not entirecircle. Some of these distributors are known as flatback distributors.

After a new grain distributor or grain distributors are installed,control processor 158 initiates a self-programming process according tothe invention. The invention permits people less skilled in the designand understanding of grain distributors such as an electrician toinitiate the initial self-programming of the grain distributor 20 inaccordance with the invention.

FIG. 14 is a flow chart partially depicting a calibration methodaccording to an embodiment of the invention. At 240, when theself-programming process is initiated after installation, distributorspout 24, 26 may be in any position. That is, spout 24, 26 may belocated such that inductive sensor 196 is in the midst of a code cluster156 or the spout may be located such that inductive sensors 196 arebetween two code clusters 156. In accordance with the invention, theself-programming process first identifies whether the distributor 20 isa circular distributor or one that has two ends at which the spout 24,26 must stop. Second, at 242, the self-programming process identifieswhether the distributor 20 is one that has five digit code clusters orsix digit code clusters 156. Five digit code clusters 156 are sufficientfor circular distributors that have up to 30 ducts. For circulardistributors 20 having more than 30 ducts, six digit code clusters 156are used. Six digit code clusters 156 need not be used for alldistributors. The use of six digit code clusters 156 may be limited forsmaller distributors 20 because of space constraints. Because of theneed to identify the ends of distributors 20 that have end positions atwhich the spout 24, 26 must reverse direction, noncircular, directionreversing distributors require six digits code clusters if they haveover 19 ducts.

Upon initiation, the program first identifies whether inductive sensors196 associated with spout 24, 26 are located between two code clustersor within a code cluster. This is accomplished by advancing the spout24, 26 until a complete or partial code cluster 156 is read. If acomplete code cluster 156 is read, the control processor 158 operatingthe inventive self-programming makes a record of the number representedby the complete code cluster 156 read. If only a partial code cluster156 is read, the control processor 158 commands the spout 24, 26 toreverse direction until inductive sensors 196 are out of the codecluster 156 and therefore between two code clusters 156. The spout 24,26 is then advanced so that the entire code cluster 156 is read. Thisalso provides information as to whether the code cluster 156 is a fivedigit or six digit code cluster 156 which can be saved.

At 244, decision is also made as to whether the code cluster 156 thathas been read is a possible end code cluster 156 that would requirereversal of the direction of the motion of the spout 24, 26. If the codecluster 156 is a possible value of an end code cluster, then the spout24, 26 is commanded to reverse direction and to read the value of theprior code cluster 156. In accordance with the invention, end codesclusters are unique, first because they are designed to read differentnumerical values when they are read in the left to right direction asopposed to being read in the right to left direction. In other wordsthey lack symmetry. End code clusters are unique, secondly, because theyrepresent large numbers relative to the numerical values of the othercode clusters 156 in the distributor 20.

This application discusses example end code clusters 156 for five digitcode clusters, though similar principles can be applied to six digitcode clusters or to code clusters having more than six digits. Oneexample a five digit end code cluster has numerical values of 19 and 25depending upon which direction the code cluster is read. The binaryvalues of the five positions in the five digit code cluster are 1, 2, 4,8 and 16. If the first, second and fifth digits are marked in the codecluster when read in a first direction, the value of the code cluster156 will be 19 because those digits are 1, 2 and 16. 1+2+16=19. If thesame code cluster is read in the opposite direction, its value will be25 because the digits that are marked are read as 1, 8 and 16,16+8+1=25. Accordingly, if the control processor 158 encounters a codecluster 156 having a value of 19 when read in a first direction and 25when read in the opposite direction, the code cluster 156 is,potentially, an end code cluster. It could also be a code cluster 156representing the nineteenth duct in a circular distributor having morethan 19 ducts. Another example end code cluster 156 has a value of 29and 23. In this case again, a five digit code cluster 156 has four datadigits when read from left to right which are the first, third, fourthand fifth positions. When read in a first direction, the binary digitshave the values of 1, 4, 8 and 16. 1+4+8+16=29. When read in a seconddirection, the digits have the values of 1, 2, 4 and 16. 1+2+4+16=23.Thus, this code combination is a potential end code. It is also possiblethat this code cluster is the 29^(th) code cluster in a circulardistributor. At 246, according to the invention, once a code cluster 156is read that is a potential end code, the control processor 158 commandsthe spout 24, 26 to stop after reading that code cluster 156 and toreverse direction to read the prior code cluster 156, if the prior codecluster 156 is not a sequential value to the possible end code clusterread, the algorithm determines that this code cluster 156 is an end codecluster and commits that information to memory.

According to the invention, end code clusters may have three qualities,their code clusters 156 have a different numerical value when read rightto left as compared to being read left to right, they are non-sequentialin numerical value with their adjacent code cluster 156 and they arerelatively large numbers as compared to the rest of the code clusters156 for the distributor.

At 248, once a verified end code cluster has been identified, thecontrol processor 158 then commands the spout 24, 26 to reversedirection to read all of the sequential code clusters 156 that existbetween the two end code clusters 156 and to identify the end codecluster at the opposite end of the grain distributor 20.

At 250, if no end code clusters are identified, control processor 158then commits to memory the fact that the distributor 20 in question is acircular distributor. In a circular distributor 20 it is possible, inaccordance with the invention, to program the operation of the circulardistributor 20 so that the spout 24, 26 will take the shortest routearound the circle to the next desired grain receiving duct based on thenumerical values of the code clusters. Grain distributors that usemicro-switch technology must return spout 24, 26 to a home positionprior to seeking a new desired position because micro-switches mustalways be approached from a single direction to accomplish accurateplacement of spout 24, 26.

For example, let us assume a flatback non-circular distributor 20 having18 ducts. This distributor then has two ducts, the first and the 18^(th)that are identified by end codes and 16 intervening ducts that areidentified by code clusters 156 having values of 3-17. (Note that thefirst and second ducts will both be associated with the first end codeand are differentiated depending on which direction spout 20, 26 istraveling when the first end code is read. Similarly, the seventeenthand eighteenth ducts will be identified by the second end code dependingon the direction of travel.) Let us also assume that after thedistributor 20 is installed, the spout 24, 26 is positioned so that thesensor is in the midst of the first end code cluster 156. According tothe invention, the spout 24, 26 is commanded to advance and inductivesensor 196 reads a partial code cluster 156. At this position, controlprocessor 158 commands the spout 24, 26 to stop and reverse direction.The spout 24, 26 then reads all five digits of the end code cluster 156and determines the value of 25 for the five digits. The spout 24, 26 isthen commanded to reverse direction again to read the end code clusteragain and reads the value of 19 because of the reversed direction. Whenthis has been done, the end 19-25 code cluster is identified as apossible end code cluster. The spout 24, 26 is then commanded to advanceagain to read the next code cluster which will be number 2. At thispoint, the algorithm has confirmed that the first cluster read was infact an end code cluster having the value of 19-25.

The fact that the next code cluster has a value of 3 that isnon-sequential and much smaller, confirms that this first code clusteris an end code cluster and it is committed to memory that this is agrain distributor that has two ends. The spout 24, 26 then advances andreads the ensuing and code clusters in sequence identifying spoutposition 2, 3, 4, 5 and so on until it reaches code cluster 17. The nextcode cluster read will also be an end code cluster which has a value of23. Because this end code cluster is out of sequence having a value of23 following 17, it will also be identified as an end code cluster andcontrol processor 158 will then commit to memory the fact that this isan end code position of the distributor 20. Once this procedure has beencompleted a single time for each distributor 20 within the system, theinformation is memorized and the distributors 20 may be operated withoutany need for operator programming of the initial location of the spout24, 26 and grain receiving ducts 36.

In another embodiment of the invention the control processor is furtherprogrammed to identify the code clusters 156 having sequential numericalvalues starting adjacent to the first end code cluster 156 until asecond probable end code cluster 156 is identified and confirmed thusidentifying all code clusters 156 associated with the distributor 20.

At 252, in another embodiment of the invention the control processor 158is further programmed to memorize a numerical value of the first codecluster 156 encountered by inductive sensor 196 and to continue countingthe code clusters 156 in sequence until the numerical value of the firstcode cluster 156 is encountered again thus confirming that thedistributor 20 is a circular distributor 20 and identifying the totalnumber of ducts in the distributor.

In another embodiment of the invention the control processor 158 isfurther programmed to identify whether a first binary digit in the codeclusters 156 alternates thereby determining that the spout is moving ina logical forward direction or if the first binary digit does notalternate determining that the spout 24, 26 is moving in a logicalbackward direction.

In another embodiment of the invention the control processor 158 isfurther programmed to repeat identifying whether the first binary digitin the code clusters 156 alternates thereby determining that the spout24, 26 is moving in the logical forward direction or if the first binarydigit does not alternate determining that the spout is moving in thelogical backward direction three times.

If distributor 20 is a circular distributor 20 control processor 158 isfurther programmed to continue advancing until the first encounteredcode cluster 156 is encountered. Then the total number of duct in thedistributor 20 is known. Control processor 158 is programmed to causespout 24, 26 to take the shortest directional route from its presentlocation to the next desired duct location. For example in a twenty ductcircular distributor, control processor 158 commands the spout toadvance four ducts to get from duct number 18 to duct number 2 ratherthan to reverse 16 duct positions to get to the same duct position.

The present invention may be embodied in other specific forms withoutdeparting from the spirit or essential attributes thereof, and it istherefore desired that the present embodiment be considered in allrespects as illustrative and not restrictive, reference being made tothe appended claims rather than to the foregoing description to indicatethe scope of the invention.

1. A grain distributor comprising a housing with an open interior; aplurality of receiving ducts extending from the housing, each receivingduct having a receiving portion in the interior of the housing; adistribution spout pivotally moveable among and stoppable at each of thereceiving portions, the distribution spout having a plurality of pivotalpositions; a drive motor connected to the housing and distribution spoutthat moves and stops the distribution spout; a coded portion with aplurality of code clusters operably coupled to the distribution spout,each code cluster including a unique series of data digits indicative ofa pivotal position of the distribution spout; a plurality of proofwindows, each proof window being associated with a receiving ductlocation; a sensor configured to sense the data digits and generatecorresponding signals, the sensor and coded portion being coupled to thedistribution spout and housing such that the sensor confronts the codedportion and such that pivotal movement of the distribution spout movesthe coded portion with respect to the sensor or moves the sensor withrespect to the coded portion, the code clusters arranged such that thedata digits of each code cluster move sequentially past the sensorwhereby the code clusters are serially read; a control processoroperably connected to the sensor, the control processor configured toreceive the signals from the sensor and to determine the pivotalposition of the distribution spout based in the signals; a timeroperably coupled to the control processor; the control processorprogrammed with an algorithm to pivot the distribution spout and toreceive and record signals from the sensor as the sensor confronts eachof the code clusters and each of the proof windows; the controlprocessor being programmed with the algorithm to associate each signalfrom each code cluster with a particular time value generated by thetimer and to memorize the particular time value associated with eachcode cluster in a long term memory; and the control processor beingprogrammed with the algorithm to associate a signal from at least one ofthe proof windows in a long term memory.
 2. The grain distributor asclaimed in claim 1, the control processor further being programmed tosense a first edge of the proof window and a second edge of the proofwindow and to save the unique time values generated by the timerassociated with each of the first edge of the proof window and thesecond edge of the proof window.
 3. The grain distributor as claimed inclaim 2, the control processor further being programmed to calculate amidpoint value between the unique time values generated by the timerassociated with the first edge of the proof window and the second edgeof the proof window and to save the midpoint value.
 4. The graindistributor as claimed in claim 4, the control processor further beingprogrammed to use the saved midpoint value to control alignment of thedistribution spout with the receiving portion of each receiving duct byoperation of the drive motor.
 5. The grain distributor as claimed inclaim 1, the control processor further being programmed to monitor theposition of the proof window while grain is being transferred to one ofthe plurality of receiving ducts from the distribution spout.
 6. Thegrain distributor as claimed in claim 5, the control processor furtherbeing programmed to send an error message if the position of the proofwindow changes while grain is being transferred to one of the pluralityof receiving ducts from the distribution spout.
 7. The grain distributoras claimed in claim 5, the control processor further being programmed toactivate a valve to stop the flow of grain if the position of the proofwindow changes while grain is being transferred to one of the pluralityof receiving ducts from the distribution spout.
 8. The grain distributoras claimed in claim 1, the control processor further being programmed toidentify a number of digits in the code clusters of the distributor. 9.The grain distributor as claimed in claim 1, the control processorfurther being programmed to identify whether the grain distributor is acircular grain distributor or a noncircular grain distributor having endpositions at which the distribution spout must reverse direction. 10.The grain distributor as claimed in claim 9, the control processorfurther being programmed to identify probable end code clusters and whena probable end code cluster is identified to read an adjacent codecluster to confirm or deny that the probable end code cluster is in factan end code cluster.
 11. The grain distributor as claimed in claim 9,the control processor further being programmed to identify a codecluster as a probable end code cluster if the code cluster has adifferent numerical value when read from left to right as compared tobeing read right to left and if the code cluster has a large numericalvalue relative to other code clusters of the grain distributor.
 12. Thegrain distributor as claimed in claim 10, the control processor furtherbeing programmed to confirm that a probable end code cluster is in facta first end code cluster.
 13. The grain distributor as claimed in claim12, the control processor further being programmed to identify the codeclusters having sequential numerical values starting adjacent to thefirst end code cluster until a second probable end code cluster isidentified and confirmed thus identifying all code clusters associatedwith the distributor.
 14. The grain distributor as claimed in claim 9,the control processor further being programmed to memorize a numericalvalue of the first code cluster encountered by the sensor and tocontinue counting the code clusters in sequence until the numericalvalue of the first code cluster is encountered again thus confirmingthat the distributor is a circular distributor and identifying the totalnumber of ducts in the distributor.
 15. The grain distributor as claimedin claim 9, the control processor further being programmed to identifywhether a first binary digit in the code clusters alternates therebydetermining that the spout is moving in a logical forward direction orif the first binary digit does not alternate determining that the spoutis moving in a logical backward direction.
 16. The grain distributor asclaimed in claim 15, the control processor further being programmed torepeat identifying whether the first binary digit in the code clustersalternates thereby determining that the spout is moving in the logicalforward direction or if the first binary digit does not alternatedetermining that the spout is moving in the logical backward directionthree times.
 17. A computer implemented method of calibrating a graindistributor for electronically controlled operation, comprising:rotating a coded portion or a first sensor and a second sensor operablycoupled to a distribution spout while unique digital code clusters eachassociated with a desired discharge position of the distribution spouton the coded portion move relative to the first sensor unit and thesecond sensor unit via a motor controlled by a control processor;detecting a first digital code cluster with the first sensor unit andthe second sensor unit which generate digital signals representing thefirst digital code cluster; sending the first digital signal to thecontroller processor; recording the first digital signal; detecting afirst edge of a first position proof window associated with the firstdigital code cluster with the second sensor unit; recording a first timevalue associated with a location of the first edge of the first positionproof window; detecting a second edge of the first position proofwindow; recording a second time value associated with a location of thesecond edge of the first position proof window; calculating a midpointvalue between the recorded first time value and the recorded second timevalue; and associating the midpoint value with the recorded digitalsignal for a location of the first position proof window.
 18. The methodas claimed in claim 17, further comprising using the midpoint value tocontrol positioning of the distribution spout in alignment with thedesired discharge position.
 19. The method as claimed in claim 17,further comprising calculating a midpoint value between the recordedfirst time value and the recorded second time value generated by thetimer associated with the first edge of the proof window and the secondedge of the proof window and saving the midpoint value.
 20. The methodas claimed in claim 19, further comprising using the saved midpointvalue to control alignment of the distribution spout with the receivingportion of each receiving duct.
 21. The method as claimed in claim 17,further comprising monitoring the location of the first position proofwindow while grain is being transferred to one of the plurality ofreceiving ducts from the distribution spout.
 22. The method as claimedin claim 21, further comprising sending an error message if the positionof the proof window changes while grain is being transferred to one ofthe plurality of receiving ducts from the distribution spout.
 23. Themethod as claimed in claim 21, further comprising activating a valve tostop the transfer of grain if the position of the proof window changeswhile grain is being transferred to one of the plurality of receivingducts from the distribution spout.
 24. The method as claimed in claim17, further comprising identifying whether the grain distributor is acircular grain distributor or a noncircular grain distributor having endpositions at which the distribution spout must reverse direction. 25.The method as claimed in claim 24, further comprising identifyingprobable end code clusters and when a probable end code cluster isidentified reading an adjacent code cluster to confirm or deny that theprobable end code cluster is in fact an end code cluster.
 26. The methodas claimed in claim 24, further comprising identifying a code cluster asa probable end code cluster if the code cluster has a differentnumerical value when read from left to right as compared to being readright to left and if the code cluster has a large numerical valuerelative to other code clusters of the grain distributor.
 27. The methodas claimed in claim 25, further comprising confirming that a probableend code cluster is in fact a first end code cluster.
 28. The method asclaimed in claim 27, the further comprising identifying the codeclusters having sequential numerical values starting adjacent to thefirst end code cluster until a second probable end code cluster isidentified and confirmed thus identifying all code clusters associatedwith the distributor.
 29. The method as claimed in claim 24, furthercomprising memorizing a numerical value of the first code clusterencountered by the sensor and continuing counting the code clusters insequence until the numerical value of the first code cluster isencountered again thus confirming that the distributor is a circulardistributor and identifying the total number of ducts in thedistributor.
 30. The method as claimed in claim 24, further comprisingidentifying whether a first binary digit in the code clusters alternatesthereby determining that the spout is moving in a logical forwarddirection or if the first binary digit does not alternate determiningthat the spout is moving in a logical backward direction.
 31. The methodas claimed in claim 15, further comprising repeating identifying whetherthe first binary digit in the code clusters alternates therebydetermining that the spout is moving in the logical forward direction orif the first binary digit does not alternate determining that the spoutis moving in the logical backward direction three times.